Modular fence system

ABSTRACT

The invention provides a modular fence system that includes a picket and a rail having upper and lower rail elements engagable together generally without fasteners. The lower rail member includes an opening having a tab extending therein. The opening is sized to allow the picket to be inserted therethrough allowing clearance for the tab. Upon assembly, the picket and the lower rail member move laterally relative to each other, allowing the tab to enter an opening formed in the picket side, thus holding the picket vertically. The upper rail member can be disposed over the picket through an opening in the upper rail member, so that engagement elements on the upper and lower rail members engage. The upper rail member opening is sized smaller than the lower rail member opening and holds the picket laterally in position, keeping the picket engaged with the tab inserted therein.

FIELD OF THE INVENTION

[0001] The invention relates to fences. More specifically, the invention relates to fences that can be assembled with a minimum of fasteners.

BACKGROUND

[0002] Fences have long been used for safety and decoration. The expense of a fence lies more in labor for construction and installation than in raw materials. Like so many other items, if there is a reduction in the overall cost of labor, the fence will become more available to more purchasers.

[0003] Some known fences attempt to reduce the installation cost by reducing the number of fasteners in the fence assembly. One example is U.S. Pat. No. 2,145,172 to Gustafson. The fence includes pickets and rails. A “C” shaped, lower rail has a lower slot sized to closely fit notches formed on both sides of the picket to reduce lateral movement. A separate upper slot is formed in the lower rail whose larger size provides sufficient room for the rail to be pivoted at different angles while the closer-fitting, lower slot still engages the notches. An upper rail telescopes over the picket and engages the lower rail by bending an arcuate facing member over the lower rail against the picket.

[0004] While the Gustafson reference can offer one plausible solution, there remains a need for more positive interaction between the pickets and rails.

SUMMARY OF THE INVENTION

[0005] The invention provides a modular fence system that includes a picket and a rail having upper and lower rail elements engagable together generally without fasteners. The lower rail member includes an opening having a tab extending therein. The opening is sized to allow the picket to be inserted therethrough allowing clearance for the tab. Upon assembly, the picket and the lower rail member move laterally relative to each other, allowing the tab to enter an opening formed in the picket side, thus holding the picket vertically. The upper rail member can be disposed over the picket through an opening in the upper rail member, so that engagement elements on the upper and lower rail members engage. The upper rail member opening is sized smaller than the lower rail member opening and holds the picket laterally in position, keeping the picket engaged with the tab inserted therein.

[0006] The invention provides a modular fence system, comprising a picket having an opening on a vertical portion of the picket; and a rail having a first rail member and a second rail member, the first rail member having an opening and a tab extending into the rail member opening, the tab being adapted to slidably engage the picket opening and support the picket in a vertical direction, the first rail member opening being sized at least as large as a cross section of the picket plus a length of the tab into the first rail member opening; and the second rail member adapted to be coupled to the picket, the second rail member having an opening sufficiently large to allow the picket to be inserted therethrough, and further adapted to be coupled to the first rail member primarily by being pressed into position.

[0007] The invention further provides a modular fence system, comprising a picket having an opening on a vertical portion of the picket; and a rail having a first rail member and a second rail member, the first rail member having an opening and a tab extending into the rail member opening, the tab being adapted to slidably engage the picket opening in a lateral direction and support the picket in a vertical direction, the first rail member opening being sized at least as large as a cross section of the picket plus a length of the tab into the first rail member opening; and the second rail member adapted to be coupled to the picket, the second rail member having an opening sufficiently large to allow the picket to be inserted therethrough and smaller than the first rail member opening, and further adapted to be coupled to the first rail member independent of fasteners.

[0008] The invention also provides a method of assembling a modular fence system having a picket with an opening in a vertical portion of the picket, a first rail member having an opening with a tab extending into the opening, and a second rail member having an opening formed therein, comprising locating the first rail member relative to the picket so that the first rail member at least partially surrounds the picket and the tab is aligned with the picket opening; engaging the tab of the first rail member at least partially with the picket opening; coupling the second rail member with the picket; and engaging the second rail member and the first rail member together independent of fasteners while the tab is engaged with the picket opening so that the rail members are restrained relative to each other and the tab is restrained in the picket opening.

Brief Description of the Drawings

[0009] A more particular description of the invention, briefly summarized above, can be realized by reference to the embodiments thereof that are illustrated in the appended drawings and described herein. However, it is to be noted that the appended drawings illustrate only some embodiments of the invention. Therefore, the drawings are not to be considered limiting of its scope, for the invention can admit to other equally effective embodiments.

[0010]FIG. 1 is a schematic perspective view of one embodiment of the invention.

[0011]FIG. 2 is a schematic cut-away view of a lower rail member of the invention.

[0012]FIG. 3 is a cut-away partially-assembled schematic of one embodiment of the invention.

[0013]FIG. 4 is a cut-away partially-assembled schematic of one embodiment of the invention where the picket is assembled with the lower rail member.

[0014]FIG. 5 is a cut-away partially-assembled schematic of one embodiment of the invention with an upper rail member partially assembled on the picket.

[0015]FIG. 6 is a cut-away partially-assembled schematic of one embodiment of the invention coupled with the lower rail member and the picket.

[0016]FIG. 7 is a cross-sectional schematic view of the upper and lower rail member in an assembled position.

[0017]FIG. 8 is a perspective schematic view of one embodiment of a second rail.

[0018]FIG. 9 is a perspective schematic view of another embodiment of the invention.

[0019]FIG. 10 is a cut-away perspective schematic view of the embodiment of FIG. 9.

Detailed Description of the Invention

[0020]FIG. 1 is a schematic perspective view of one embodiment of the invention. A modular system 10 generally includes one or more rails and one or more pickets. The rails and pickets can be any reasonable shape and size as may be appropriate to the particular design that still allows coupling of the rails and pickets. Generally, the modular system will include at least two rails 14, 24. The rails can be structurally similar or different, as would be appropriate to a particular design. Further, the rails and/or pickets can be made of any structural materials as appropriate. Suitable materials could include, without limitation, metals, plastics, composites, glass, and any other structural material capable of being formed into a fence.

[0021] In the embodiment shown, at least one of the rails, such as the rail 14, includes at least two portions, an upper rail member 16 and a lower rail member 18. It is to be understood that the rail 14 could include other members as well. The upper rail member 16 includes an engagement element 30 and the lower rail member 18 includes a corresponding engagement element 28. In at least one embodiment, it is advantageous that the engagement elements are able to engage one another independent of separate fasteners, such as bolts, screws, cables, and so forth, by being pressed into position, either manually or with tools. Thus, the engagement elements 28, 30 are designed with proper clearances, steps, structural flexibility, or any other aspect known to those with ordinary skill in the art, given the disclosure contained herein.

[0022]FIG. 2 is a schematic cut-away view of a lower rail member of the invention. Similar elements are similarly labeled throughout the figures contained herein. In at least one embodiment, the lower rail member 18 generally includes a web 21 and a pair of flanges 23 in at least one embodiment. The engagement element 28 can be located on one or more of the flanges 23. An opening 22 can be formed in the web 21. A tab 20 can extend into the opening 22, for example, from the side of the opening. Generally, the opening 22 is sized such to allow the picket to be inserted therethrough with sufficient clearance for the tab 20 extending in the opening. It is to be understood that the lower rail member 18 and opening 22 can be of various shapes and sizes as can be appropriate to the particular design in keeping with the claims recited herein.

[0023]FIGS. 3-6 illustrate a non-limiting, exemplary assembly of the picket with the upper and lower rail members. In general, the picket 12 is coupled to the lower rail member 18, the tab 20 is slidably engaged with the picket 12, and the upper rail member 16 is disposed around the picket 12 and coupled to the lower rail member and consequently to the picket as well. The assembly allows the two rail members to be securely coupled to each other and the picket. The term “coupled,” “coupling,” and like terms are used broadly herein and can include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, directly or indirectly with intermediate elements, one or more pieces of members together and can further include integrally forming one functional member with another. The coupling can occur in any direction.

[0024]FIG. 3 is a cut-away partially-assembled schematic of one embodiment of the invention. The lower rail member 18 can be placed over the picket 12 using the opening 22. The opening 22 is sized such that the picket 12 can pass through the opening 22 with some clearance for the tab 20. An opening 26 formed in the picket 12, such as in a vertical side, is sized to allow the tab 20 to be at least partially inserted therein. One or more engagement elements 28 that are coupled to the rail member 18 can be sized, shaped, and positioned to engage one or more corresponding engagement elements on the upper rail member, shown in FIG. 1.

[0025]FIG. 4 is a cut-away partially-assembled schematic of one embodiment of the invention where the picket is being assembled with the lower rail member. The tab 20 can be aligned with the opening 26 in the picket. The picket 12 and the lower rail member 18 can be moved laterally with respect to each other by either the rail moving laterally to the picket or the picket moving laterally to the rail or both. The tab 20 can be at least partially inserted into the opening 26. In at least one embodiment, this interaction restricts the vertical movement of the picket relative to the lower rail member 18. However, clearance space behind the rail distal from the tab 20 in the opening 22 would otherwise allow the picket 12 to become uncoupled from the tab 20 without supplemental restriction in movement.

[0026]FIG. 5 is a cut-away partially-assembled schematic of one embodiment of the invention with an upper rail member partially assembled on the picket. The supplemental restriction of movement can occur through the additional coupling of the upper rail member 16 with the lower rail member 18. The upper rail member is formed to matingly engage or otherwise couple with the lower rail member 18. Similar to the lower rail member 18, the upper rail member 16 can include a web having a opening 32 disposed therethrough and one or more flanges having one or more engagement elements 30. As described above, the engagement elements 30 on the upper rail member are adapted to engage or otherwise couple to the engagement elements 28 on the lower rail member 18.

[0027] Thus, while the tab 20 is engaged with the opening 26 in the picket 12, the upper rail member 16 can be disposed over the picket 12, using the opening 32 in the upper rail member, and be coupled to the lower rail member 18. The opening 32 in the upper rail member 16 is generally smaller than the opening 22 in the lower rail member 18. Thus, the opening 32 in the upper rail member restricts the movement of the picket 12 to a greater extent than the opening 22 in the lower rail member. Sufficient restraint, such as through friction, between the upper rail member 16 and the lower rail member 18 restricts the lateral movement of the upper rail member 16 relative to the lower rail member 18. Thus, the picket is sufficiently restricted in position, so that it does not disengage from the tab 20 when the upper rail member 16 is coupled with the lower rail member 18.

[0028]FIG. 6 is a cut-away partially-assembled schematic of one embodiment of the invention coupled with the lower rail member and the picket. The alignment of the opening 32 in the upper rail member 16 with the opening 22 in the lower rail member 18 in combination with the relative sizes of the openings 32, 22 restrict the lateral movement of the picket 12 relative to the upper and lower rail members. Vertical movement is restricted by the tab 20 interacting with the opening 26. Further, the modular system 10 can be more fully formed in like fashion with successive pickets, as desired.

[0029] The rail 14 can be disposed at the various vertical locations along the length of the picket 12. In many cases, the modular system 10 will include a plurality of rails. In some systems, the rails can simply be members having an opening disposed therethrough, such as shown in FIG. 8 below. In other embodiments, the other rail can be formed in like fashion as described above regarding the rail 14.

[0030]FIG. 7 is a cross-sectional schematic view of the upper and lower rail members in an assembled position. In the assembled condition, the rail 14 can include the upper rail member 16 and the lower rail member 18. In at least one embodiment, the opening 22 can be formed in a web 21 of the lower rail member 18. A tab 20 can extend at least partially into the opening 22 formed in the lower rail member 18. The lower rail member 18 can include one or more flanges 23. The flanges 23 can include one or more engagement elements 28. The engagement elements 28 are adapted to matingly engage with corresponding engagement elements on the upper rail member.

[0031] Similarly, an opening 32 can be formed in a web 17 of the upper rail member 16. The upper rail member 16 can include one or more flanges 19. One or more of the flanges 19 can include at least one engagement element 30. In general, the engagement elements 28, 30 can be formed to engage each other in some fashion to restrict reverse movement of the picket, as would be known to those with ordinary skill in the art, given the discussion disclosed herein.

[0032]FIG. 8 is a perspective schematic view of one embodiment of a second rail. The second rail member 24 can be included with the modular system 10 at a different elevation than the rail 14 along the picket. For example, the second rail member 24 can be useful in providing additional lateral stability to the picket 12 in addition to the rail 14 described above. In at least one embodiment, the rail 24 can include an opening 34 through which the picket 12 can be inserted. For example, the opening 34 can correspond generally to the size of the opening 32 in the upper rail member 16, described in previous figures. Alternatively and without limitation, the rail 24 can be designed the same or similar to the rail 14 with the various features and rail elements described herein.

[0033]FIGS. 9-10 illustrate another embodiment of the invention. Similar features are illustrated and numbered as described above. In at least this embodiment, the rail 14 includes an upper rail member 16 that is dimensioned to slidably engage the picket 12 and at least partially overlap the lower rail member 18.

[0034]FIG. 9 is a perspective schematic view of another embodiment of the invention. An upper rail member 16 of the rail 14 includes one or more openings 32. The opening 32 is generally sized to allow a picket 12 to pass therethrough with some clearance. The upper rail member 16 includes one or more engagement elements 30. The engagement element 30 can be disposed, for example and without limitation, on a lower edge of a flange 19.

[0035] A lower rail member 18 can include an opening 22 disposed therethrough. The lower rail member 18 can include one or more tabs 20 extending into the opening 22 and sized to engage an opening 26 formed in the picket 12. The opening 22 is generally sized such to allow clearance of a picket 12 to pass therethrough in addition to the length of the tab 20 extending into the opening 22. An engagement element 28, such as an edge, can be formed on the lower rail member 18, for example, at one or more flanges 23.

[0036] Upon assembly, the lower rail member 18 can be inserted over the picket 12 or the picket 12 can be inserted through the lower rail member 18, aligning the tab 20 on the lower rail member 18 with an opening 26 formed in the picket 12. The picket 12 and lower rail member 18 can be laterally moved relative to each other, so that the tab 20 at least partially engages the opening 26 in the picket. The upper rail member 16 can be disposed over the picket 12, so that picket 12 extends through the opening 32 formed in the upper rail member 16.

[0037]FIG. 10 is a cut-away perspective schematic view of the embodiment of FIG. 9. The upper rail member 16 is shown fully engaged with the lower rail member 18. The engagement element 30 is shown coupled with the engagement element 28 on the lower rail member 18. The picket 12 extends through the opening 32 in the upper rail member 16 and the opening 22 through the lower rail member 18. The tab 20 is engaged with the opening 26. The movement of the picket 12 away from the tab 20 is restricted by the upper rail member 16, and in at least one embodiment, by the size of the opening 32 in the upper rail member. The relative motion between the upper rail member 16 and the lower rail member 18 is restricted by coupling of the engagement elements 28, 30. Thus, the rail is securely coupled with the upper and lower rail members 16, 18, both vertically and laterally. While the foregoing is directed to various embodiments of the present invention, other and further embodiments can be devised without departing from the basic scope thereof. For example, the various methods and embodiments of the invention can be included in combination with each other to produce variations of the disclosed methods and embodiments, as would be understood by those with ordinary skill in the art, given the teachings described herein. Also, a plurality of the embodiments could be used in conjunction with each other for a given application. Also, the directions such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of the actual device or system or use of the device or system. The device or system can be used in a number of directions and orientations. Further, the order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Additionally, any headings herein are for the convenience of the reader and are not intended to limit the scope of the invention.

[0038] Further, any references mentioned in the application for this patent as well as all references listed in the information disclosure originally filed with the application are hereby incorporated by reference in their entirety to the extent such can be deemed essential to support the enabling of the invention(s). However, to the extent statements might be considered inconsistent with the patenting of the invention(s), such statements are expressly not meant to be considered as made by the Applicant. 

1. A modular fence system, comprising: a. a picket having an opening on a vertical portion of the picket; and b. a rail having a first rail member and a second rail member, i. the first rail member having an opening and a tab extending into the rail member opening, the tab being adapted to slidably engage the picket opening and support the picket in a vertical direction, the first rail member opening being sized at least as large as a cross section of the picket plus a length of the tab into the first rail member opening; and ii. the second rail member adapted to be coupled to the picket, the second rail member having an opening sufficiently large to allow the picket to be inserted therethrough, and further adapted to be coupled to the first rail member primarily by being pressed into position.
 2. The system of claim 1, wherein the second rail member is adapted to be pressed into position independent of fasteners.
 3. The system of claim 1, wherein the picket opening is formed on a side of the picket and the tab extends in a lateral direction into the first rail member opening, so that lateral movement between the first rail member and the picket engages the tab at least partially into the picket opening.
 4. The system of claim 1, wherein the first rail member comprises a first engagement element and the second rail member comprises a second engagement element, the first and the second engagement elements adapted to matingly engage each other.
 5. The system of claim 1, wherein the second rail comprises a channel having a web and at least two flanges and the second engagement element is formed on at least one the two flanges and adapted to matingly engage the first rail member.
 6. The system of claim 1, wherein the first rail member comprises a channel having a web and at least two flanges, wherein the opening and the tab are formed in the web.
 7. The system of claim 1, further comprising a second rail adapted to engage the picket at a different elevation than the first rail.
 8. The system of claim 1, wherein the first rail member is sized to allow the second rail member to at least partially overlap the first rail member.
 9. A modular fence system, comprising: a. a picket having an opening on a vertical portion of the picket; and b. a rail having a first rail member and a second rail member, i. the first rail member having an opening and a tab extending into the rail member opening, the tab being adapted to slidably engage the picket opening in a lateral direction and support the picket in a vertical direction, the first rail member opening being sized at least as large as a cross section of the picket plus a length of the tab into the first rail member opening; and ii. the second rail member adapted to be coupled to the picket, the second rail member having an opening sufficiently large to allow the picket to be inserted therethrough and smaller than the first rail member opening, and further adapted to be coupled to the first rail member independent of fasteners.
 10. The system of claim 9, wherein the first rail member comprises a first engagement element and the second rail member comprises a second engagement element, the first and the second engagement elements being adapted to matingly engage each other.
 11. The system of claim 10, wherein the second rail member comprises a channel shape having a web and at least two flanges and the second engagement element is formed on at least one of the two flanges and adapted to matingly engage the first rail member.
 12. The system of claim 11, wherein the first rail member comprises a channel shape having a web and at least two flanges and the opening and the tab are formed in the web.
 13. The system of claim 12, wherein the flanges from the first rail member and the flanges from the second rail member matingly engage.
 14. The system of claim 9, wherein the first rail member is sized to allow the second rail member to at least partially overlap the first rail member.
 15. The system of claim 9, further comprising a second rail adapted to engage the picket at a different elevation than the first rail.
 16. A method of assembling a modular fence system having a picket with an opening in a vertical portion of the picket, a first rail member having an opening with a tab extending into the opening, and a second rail member having an opening formed therein, comprising: a. locating the first rail member relative to the picket so that the first rail member at least partially surrounds the picket and the tab is aligned with the picket opening; b. engaging the tab of the first rail member at least partially with the picket opening; c. coupling the second rail member with the picket; and d. engaging the second rail member and the first rail member together independent of fasteners while the tab is engaged with the picket opening so that the rail members are restrained relative to each other and the tab is restrained in the picket opening.
 17. The method of claim 16, wherein engaging the tab of the first rail member at least partially with the picket opening comprises laterally moving the first rail member, picket, or both relative to each other.
 18. The method of claim 16, wherein the first and the second rail members each comprises at least two flanges extending and wherein engaging the second rail member and the first rail member comprises engaging the flanges of each rail member.
 19. The method of claim 16, wherein the second rail member at least partially overlaps the first rail member.
 20. The method of claim 16, wherein coupling the second rail member with the picket comprises protruding the picket through the second rail member opening. 